Filter media for filtration of cooking fumes

Abstract

A kitchen appliance has a compressible filter media block for removing odor-causing contaminants from cooking fumes. The sintered-fiber media exhibits low pressure drop and high flow rate. Embedded sorbent particles are adhered to the media block, preferably via sintering, thus leaving a substantial proportion of adsorbent surface area exposed for filtration purposes. The media block can be elastic or viscoelastic making it useful in retrofit applications for use in filtration circuits not originally designed to accommodate a filter. In preferred embodiments, the media block is composed of sintered plastic fibers wherein the sorbent particles are adhered thereto via sintering.

What is claimed is: 
     
       1. A kitchen appliance comprising an air-venting circuit configured to draw cooking fumes, and a filter disposed in said air-venting circuit to remove odor-causing contaminants from the cooking fumes prior to discharge thereof, said filter comprising a conformable media block that re-expands following compression thereof to conform to an available cross-sectional area of said air-venting circuit where the filter is installed, said media block further comprising reinforcing fibers having a Denier of 100 to 300 and a staple length of 25-45 mm, said reinforcing fibers being present at a rate of 5-20% total fiber weight in said media block. 
     
     
       2. The appliance of  claim 1 , said media block comprising sintered plastic fibers and sorbent particles adhered to said plastic fibers via sintering. 
     
     
       3. The appliance of  claim 1 , said media block comprising non-woven fabrics formed into a conformable block and impregnated with sorbent particles. 
     
     
       4. The appliance of  claim 1 , said appliance being an over-the-range appliance, said cooking fumes being generated beneath said appliance. 
     
     
       5. The appliance of  claim 1 , said media block having viscoelastic properties such that it exhibits slow-return hysteresis following compression and removal of the compressive force. 
     
     
       6. The appliance of  claim 5 , said media block having an overall void fraction of at least 80%. 
     
     
       7. The appliance of  claim 2 , said plastic fibers comprising composite fibers comprising a thermoset core material and a thermoplastic sheath material, said fibers being sintered via said thermoplastic sheath material. 
     
     
       8. The appliance of  claim 7 , said thermoplastic sheath material having a melting point of 125° C. to 135° C. 
     
     
       9. The appliance of  claim 7 , said sorbent particles being adhered to said thermoplastic sheath material in such a manner as to leave a substantial proportion of outer surfaces of said particles exposed to void space within the media block. 
     
     
       10. The appliance of  claim 7 , said thermoset core material comprising polyester having a specific gravity of 1.2 to 1.5, said thermoplastic sheath material comprising polyethylene having a specific gravity of 0.85 to 0.95. 
     
     
       11. The appliance of  claim 7 , said composite fibers having a Denier of 10-20 and a staple length of 30-70 mm. 
     
     
       12. The appliance of  claim 1 , said media block having a compressibility of 0.5-1 in/psi. 
     
     
       13. The appliance of  claim 2 , said sorbent particles comprising coconut-shell derived activated carbon. 
     
     
       14. The appliance of  claim 1 , said media block being viscoelastically compressible.